What is the normal operating temp on the Dana 35 rearend?? I changed the pinion seal and diff cover gasket and put new gear oil in.
I marked the pinion nut, yoke and 3rd member, and when I went to tighten down the nut after seal replacement I couldnt get the mark on the nut back in its original placement maybe around 5-6mm off.
After a 20 min test drive, I put my hand on the diff cover and coulnt keep my hand on it for more than a second.......
there arent any leaks, but that hi temp is scary!!!! I plan on rolling out to New Jersey this friday!!! So obviuosly this concerns me!

I wouldn't think it would heat up that much in a 20 minute drive. If you just had a gear job done, then yes, I've seen them get that warm that quick.

I've shot my D44 with an IR thermometer when I've been out rock crawling. After a hard day on the trail in hot weather, mine was about 140~150 F. Quite a few others in the group were 20 F higher. I run synthetic fluid, they were running dino oil. Not real scientific but that is how it was.

Stu, that sucker was HOT!!!! there wasnt a gear job involved, I think I shouldve marked the pinion shaft and the nut, not the yoke and 3rd member. I did use plain jane gear oil too....I think I will be driving the wifes Kia Sorrento to N.J just for the comfort factor.....

I think you have succeded in overcrushing the crush sleeve. it'll need to be replaced. Do not drive it like this, if you have overtorqued the pinion preload, you WILL destroy the bearings.

Too many folks seem to think that you can get the same torque by 'aligning' the nut again... wrong. You must reproduce the exact rotational torque to have the same preload on the bearings. (Accounting for drag of new seal, add about 3 inch pounds.) Yes, that requires the axles be pulled out of the diff.

Yup... gear stuff is more exacting than almost anything else on a Jeep.

I think you have succeded in overcrushing the crush sleeve. it'll need to be replaced. Do not drive it like this, if you have overtorqued the pinion preload, you WILL destroy the bearings.

Too many folks seem to think that you can get the same torque by 'aligning' the nut again... wrong. You must reproduce the exact rotational torque to have the same preload on the bearings. (Accounting for drag of new seal, add about 3 inch pounds.) Yes, that requires the axles be pulled out of the diff.

Yup... gear stuff is more exacting than almost anything else on a Jeep.

I'm pretty sure I over crushed the sleeve... after I get back from vacation I am going to remove the carrier and check the bearings for any discoloring and if every thing seems fine I will just use a new crush sleeve retorq it down to spec..... I did drive it already I just hope I didnnt eff anything up (yet)